Broken Mast...Repair or replace

[hemi]

As a general question to the forum, I would like opinion of what my options may be related to a broken mast.

General Information: 52' Cutter, Aluminum mast built in Cape Town South Africa 1990, 3 spreader rig, 3 mast sections, I dimension is roughly 73', Standing rigging 1/2" strand.

What happened: Starboard shroud turnbuckle failed 300 miles offshore in a 35 -45 kt blow. Mast separated fairly clean (+/- 2 inches) within second section above lower spreaders.

Basic question is can a mast section be repaired with sleeving assuming the correct sectional parts can be obtained? Would this approach put an unacceptable amount of weight aloft?

At what point do you scrap the spar and look for a replacement?

I realize that these questions are difficult to answer without more details or photos but will try to provide additional information as requested.
Thanks.

[Douglas]

I have been studying a similar situation, myself. Well, if your mast is in sections already, you surely can put in another sleeve and re-join the two ends.

Yes, additional weight aloft is a valid concern, and should be considered.

Yes, without the benefit of photos, it is hard to visualize your exact requirement.

If you need to get back out sailing quickly, and save money, think repair, before thinking replacement.

Of course you will be checking the other turnbuckles for potential failure too.

Try to stay away from welding on the mast section itself.

A main reason for total mast replacement would be many dented-buckles in the mast wall, in various places. Aluminum mast "metal fatigue", in structurally critical places, evidenced by line cracking away from fittings, and excessive crazing on an anodized aluminum mast surface near structural parts or elsewhere.

[Brion Toss]

Hello,
Great post from Douglas. I'm just curious to hear more details, for forensic reference. See, every rigging failure, though it might cost you dearly, can be an opportunity to learn how to prevent other failures, for you and the world. So tell us more about the turnbuckles, sea conditions, state of tune, age of rig, etc., okay?
Fair leads,
Brion Toss